Waterproof Connector Insulative Shell Insert-Molding
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Solution Overview
Problem
Existing waterproof electrical connectors face challenges in achieving uniform distribution of insulative materials during the insert-molding process, particularly when a sub shell is affixed to a shielding shell, leading to instability and potential gaps that compromise the waterproof seal.
Innovation Solution
The design incorporates an insulative housing with a base and tongue portion, a metallic shielding plate, and a metal shell, where the insulative shell is insert-molded with the metal shell to form a receiving space, and glue materials flow through specific holes to form a glue wall, sealing gaps between the shielding shell and the insulative housing, while the metal shell is affixed to the shielding shell via spot welding, enhancing structural stability and waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulative shell is insert-molded with the sub shell affixed to the shielding shell, then the waterproof seal is formed, but the insulative materials are difficult to have a well-distributed formation
Solution Approach 1:
The patent divides the molding process into two separate stages: first molding the insulative shell independently, then separately affixing the sub shell to the shielding shell and assembling with the insulative shell. This segmentation allows each component to be manufactured and assembled separately, avoiding the material distribution problems that occur when trying to mold multiple affixed components simultaneously.
2Stability of the object's composition
If the sub shell is affixed to the shielding shell before insert-molding, then the structural assembly is formed, but instability and potential gaps compromise the waterproof seal
Solution Approach 1:
The patent performs preliminary actions by first molding the insulative shell with its receiving cavity prepared in advance, then separately preparing the metal shell with the sub shell affixed to the shielding shell. This preliminary preparation of each component ensures proper fit and eliminates gaps when assembled together, maintaining both structural stability and waterproof reliability.
3Ease of manufacture
If the insulative shell is insert-molded directly with the shielding shell, then the manufacturing process is simplified, but the structural strength and waterproofing are reduced
Solution Approach 1:
The patent employs composite material construction by combining the insulative shell (first material) with the metal shell containing the sub shell and shielding shell (second material). This composite structure integrates materials with different properties - the insulative material provides electrical isolation and sealing, while the metal components provide structural strength and shielding, achieving both ease of manufacture and high structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration ensures a stable and effective waterproof seal by uniformly distributing insulative materials and providing structural strength, reducing the likelihood of instability and improving the connector's performance on a printed circuit board.
Implementation Method 1
an insulative shell insert-molded with the metal shell and enclosing the shielding shell
Implementation Method 2
glue materials flow through specific holes to form a glue wall, sealing gaps between the shielding shell and the insulative housing
Implementation Method 3
the metal shell is affixed to the shielding shell via spot welding, enhancing structural stability and waterproofing
Data Source
AI summary
An electrical connector includes: an insulative housing having a base portion and a tongue portion extending forwardly from the base portion; a number of terminals retained in the insulative housing; a shielding shell attached to the insulative housing to form a receiving space; a metal shell for mounting on a printed circuit board, the metal shell being affixed to the shielding shell; and an insulative shell insert-molded with the metal shell and enclosing the shielding shell.